US20060191163A1 - Footwear and related method of manufacture - Google Patents
Footwear and related method of manufacture Download PDFInfo
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- US20060191163A1 US20060191163A1 US11/065,851 US6585105A US2006191163A1 US 20060191163 A1 US20060191163 A1 US 20060191163A1 US 6585105 A US6585105 A US 6585105A US 2006191163 A1 US2006191163 A1 US 2006191163A1
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- Prior art keywords
- heel
- midsole
- segment
- medial
- lateral
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- A—HUMAN NECESSITIES
- A43—FOOTWEAR
- A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
- A43B7/00—Footwear with health or hygienic arrangements
- A43B7/14—Footwear with health or hygienic arrangements with foot-supporting parts
- A43B7/16—Footwear with health or hygienic arrangements with foot-supporting parts with elevated heel parts inside
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- A—HUMAN NECESSITIES
- A43—FOOTWEAR
- A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
- A43B13/00—Soles; Sole-and-heel integral units
- A43B13/02—Soles; Sole-and-heel integral units characterised by the material
- A43B13/12—Soles with several layers of different materials
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- A—HUMAN NECESSITIES
- A43—FOOTWEAR
- A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
- A43B7/00—Footwear with health or hygienic arrangements
- A43B7/14—Footwear with health or hygienic arrangements with foot-supporting parts
- A43B7/1405—Footwear with health or hygienic arrangements with foot-supporting parts with pads or holes on one or more locations, or having an anatomical or curved form
- A43B7/1415—Footwear with health or hygienic arrangements with foot-supporting parts with pads or holes on one or more locations, or having an anatomical or curved form characterised by the location under the foot
- A43B7/144—Footwear with health or hygienic arrangements with foot-supporting parts with pads or holes on one or more locations, or having an anatomical or curved form characterised by the location under the foot situated under the heel, i.e. the calcaneus bone
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- A—HUMAN NECESSITIES
- A43—FOOTWEAR
- A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
- A43B9/00—Footwear characterised by the assembling of the individual parts
- A43B9/04—Welted footwear
- A43B9/06—Welted footwear stitched or nailed through
Definitions
- the present invention relates to footwear and, more particularly, to a footwear construction and method for making the same.
- footwear that provides flexibility and stability.
- Such footwear is targeted toward individuals whose lifestyle and/or profession demand high levels of physical activity, for example, traveling on foot for significant distances, or frequently traversing rugged terrain or worksites.
- footwear constructions provide one of flexibility and stability, but usually not both because the features required for these characteristics typically negate one another.
- one construction known for its flexibility is a San Crispino construction, which may be incorporated into tactical, military, work or hiking boots.
- an upper is sewn to a flat, foot shaped insole board.
- a first part of a lower edge of the upper is stitched to a top surface of the insole board.
- a remaining part of the edge is wrapped over the periphery of the insole-board, and folded back under the board, against the bottom surface of the board.
- a flat outsole is glued over the bottom surface of the insole board and any part of the upper that is folded against the bottom side of the insole board.
- the aforementioned problems are overcome by the present footwear construction including a midsole that has medial and lateral flanges, and that defines a recess in the heel.
- An upper can be stitched to the medial and lateral flanges along a lower periphery of the upper.
- the part of the midsole defining the recess can nest in a heel wedge.
- An outsole can be secured to the heel wedge generally in the heel region and to the midsole generally in the forefoot region.
- medial and lateral flanges can be segmented into separate or non-contiguous heel and forefoot flange segments.
- the heel wedge can include a concealment flange disposed adjacent the upper in the area between the heel and forefoot flange segments.
- a foot bed interfits over the midsole, and nests at least partially within the heel recess.
- the midsole can be constructed from a dual density material, with a softer density material being located in the forefoot region, generally below the ball of a wearer's foot.
- the footwear construction is manufactured by: providing an upper and including a peripheral allowance; joining the peripheral allowance with a midsole including a medial forefoot flange segment and a medial heel flange segment, and a lateral forefoot flange segment and a lateral heel flange segment, the midsole including a heel region and defining a heel recess in the heel region; and joining an outsole with the midsole.
- a heel wedge can be positioned between the midsole and outsole in the heel region.
- a foot bed can be positioned over the midsole and at least partially in the heel recess.
- the present footwear construction provides an unparalleled combination of flexibility and stability.
- the medial and lateral midsole flanges stitched to the upper makes this region flexible, yet well-supported.
- the midsole heel recess provides extraordinary stability for the ankle and heel of a wearer. Further coupled with an optional heel wedge, the footwear becomes even more stable, but still capable of absorbing heel shock.
- FIG. 1 is side elevational view of an article of the present footwear construction
- FIG. 2 is an exploded perspective view of the footwear
- FIG. 3 is a sectional view of the footwear taken along line 3 - 3 of FIG. 1 ;
- FIG. 4 is a sectional view of the footwear taken along line 4 - 4 of FIG. 1 ;
- FIG. 5 is a sectional view of the footwear taken along line 5 - 5 of FIG. 1 ;
- FIG. 6 is a bottom perspective view of the footwear showing the upper joined with the midsole.
- FIG. 1 A shoe incorporating an embodiment of the footwear construction is shown in FIG. 1 and generally designated 10 .
- the construction is described in connection with a 3 ⁇ 4 height tactical boot; however, the construction is well suited for use with any other type of soled footwear.
- the shoe 10 includes an upper 20 , a midsole 30 and an outsole 50 .
- An optional heel wedge 60 can be included, but is not required.
- the midsole shown better in FIG. 2 , includes a medial flange 32 and a lateral flange 36 , which optionally can be subdivided into a medial forefoot flange segment 33 and a medial heel flange segment 35 , and a lateral forefoot flange segment 37 and a lateral heel flange segment 39 , respectively.
- the midsole can also define a heel recess 34 .
- the upper can include a lower peripheral allowance 22 , which can be secured to at least one of the flange segments noted above.
- the term “arch region” refers generally to the portion of the shoe corresponding to the arch of the wearer's foot; the term “forefoot region” refers generally to the portion of the shoe forward of the arch region corresponding to the forefoot (e.g., the ball, phalanges, and toes) of a wearer's foot; and the term “heel region” refers generally to that portion of the shoe rearward of the arch region corresponding to the heel of the wearer's foot.
- the forefoot region 82 , arch region 84 and heel region 86 are generally identified in FIG. 1 , however, it is to be understood that delineation of these regions may vary depending upon the configuration of the footwear.
- the upper 20 is generally conventional and will not be described in detail. Suffice it to say that the upper 20 includes vamp 21 , quarters 23 and backstay 25 . With reference to FIG. 2 , the upper 20 includes a lower portion that transitions to an allowance 22 , also referred to as a peripheral allowance.
- the peripheral allowance 22 is joined with the midsole 30 as described in more detail below. Such joining may be accomplished by stitching, stapling, cementing, riveting, or any other type of fastening.
- the upper 20 can be manufactured from leather, canvas, nylon, combinations of these materials, or other suitable materials, and can include a liner, waterproof or otherwise, (not shown) or other conventional accessories.
- the midsole includes a medial flange 32 and a lateral flange 36 .
- the medial flange 32 can be segmented into a medial forefoot flange segment 33 and a medial heel flange segment 35 .
- the medial forefoot flange segment 33 and a medial heel flange segment 35 can be non-contiguous with one another or separated from one another by a distance.
- a first recess 43 separates the segments.
- the lateral flange 36 can be segmented into a lateral forefoot flange segment 37 and a lateral heel flange segment 39 .
- the lateral forefoot flange segment 37 and a lateral heel flange segment 39 can also be non-contiguous with one another or separated from one another by a distance. In the embodiment shown, a second recess 45 separates these segments. Although not shown, the lateral and medial segments can traverse the heel and/or toe of the footwear and connect with one another as desired. In such an embodiment, the toe 51 and heel 59 guards can be eliminated and/or shortened.
- the midsole 30 can define a heel recess 34 .
- This heel recess 34 can be defined in the heel region of the footwear and extend forward to the arch region, and in some cases, the forefoot region as desired.
- the heel recess 34 can be configured to fit at least partially in the heel wedge recess 62 , described below, and to receive at least the foot bed, described below.
- the midsole 30 can optionally include a ridge 47 on its bottom surface that cooperates with a forward portion 66 of the heel wedge 60 to position the midsole 30 over the outsole 50 and/or heel wedge 60 .
- the midsole 30 can be constructed from one or more materials, each of a different density.
- the flanges 32 and 36 can be constructed from a relatively hard ethyl vinyl acetate (EVA) or rubber, while the portion 31 of the midsole corresponding to the center of the wearer's foot along the axis of the foot, and/or corresponding to the ball of the wearer's foot, can be constructed from a softer EVA or softer rubber to provide improved flexibility and/or cushion in this area.
- EVA ethyl vinyl acetate
- certain components such as the flanges can be constructed from a completely different material, such as polyurethane, where it is expected that those components will undergo additional structural stresses, for example, where the flanges 32 , 36 are stitched in a region of moderate to high flex.
- the upper 20 can be joined with the midsole 30 .
- the peripheral allowance 22 can be stitched to the segments 33 , 35 , 37 and 39 .
- the lower peripheral allowance 22 can be wrapped over the upper surface 72 of the segments, around the edge 74 of the segments, and folded back under against the lower surface 76 of the segment and/or midsole.
- Stitching 70 can pass through the lower peripheral allowance, the upper surface, the lower surface and then in reverse direction multiple times to secure the allowance to the respective segment. This stitching can remain visible, as shown in FIG. 1 to enhance the aesthetics of the footwear as desired.
- the allowance 22 can be stitched directly to the midsole 30 , i.e., not the segments, to further secure the upper and midsole.
- the stitching 70 in this region can pass through the midsole 30 and allowance 22 , and then back through the midsole 30 , multiple times to secure the upper to the midsole.
- the stitching 70 can then transition to pass through the segments on opposite sides of the recesses 43 , 45 .
- the stitching 70 can be concealed as desired, for example by the flange 64 , as described below.
- the upper 20 and midsole 30 can be joined with other fastening mechanisms, such as cement, rivets, staples and the like as desired.
- An optional footbed 80 can be inserted in the interior of the footwear 10 and placed above the midsole 30 .
- the footbed 80 can rest at least partially in the heel recess 34 in the heel and/or arch regions as desired.
- the footbed 80 can rest above the midsole 30 in the forefoot region.
- the footwear 10 can include an optional heel wedge 60 .
- the heel wedge shown in FIGS. 2-5 is a separate component adapted to fit between the midsole 30 and the outsole 50 , generally in at least the heel region 86 of the footwear.
- the heel wedge can also be constructed to be an integral part of the outsole as the application requires.
- the heel wedge 60 can be constructed of a cushioning material, such as EVA, to improve cushioning in the heel and/or arch regions of the footwear.
- the heel wedge 60 can alternatively be constructed from a denser material, such as polyurethane to add stability to regions of the footwear as desired;
- the heel wedge 60 includes a secondary recess, also referred to as a heel wedge recess 62 .
- This heel wedge recess 62 can be configured to receive therein the midsole 30 in the heel 76 and/or arch 74 regions.
- the recess 62 is configured so that at least a portion of the midsole 30 defining the heel recess 34 fits in the recess 62 .
- the secondary recess 62 can be of a depth such that midsole 30 in the heel region nests within the recess 62 so that the medial heel flange segment 35 and lateral heel flange segment 39 protrude over the sides of the recess to provide an aesthetically pleasing and flush contour with the remainder of the heel wedge 60 that is visible.
- the heel wedge 60 can also include at least one upwardly extending flange 64 .
- This flange 64 can extend upward on both the medial and lateral sides of the footwear 10 as the application requires. As shown in FIG. 2 , flanges 64 can extend upward between the medial forefoot flange segment 33 and a medial heel flange segment 35 , as well as between the lateral forefoot flange segment 37 and a lateral heel flange segment 39 . Where these segments form recesses 43 , 45 therebetween, the flanges 64 can be disposed within those recesses on opposite sides of the footwear, respectively.
- the flanges 64 can also be of a height such that they extend above the flanges 32 , 36 , and are secured to a portion of the upper 20 in these areas.
- the flanges can be of sufficient rigidity so that they form an external shank to add stability to the footwear in the heel and/or arch regions of the footwear 10 .
- the outsole 50 can include upwardly extending flanges (not shown) that are positioned and operate similarly to the flanges 64 of the heel wedge described above.
- the heel wedge 60 can include an internal shank (not shown) constructed of steel plastic or other material to add the desired structural rigidity to the footwear as desired.
- the shank can be simply secured to the bottom of the heel wedge in the arch region 74 of the shoe.
- the shank can be secured to other components of the shoe as desired, and may overlap with the other regions, for example, the forefoot 72 region and heel 76 region.
- the outsole 50 is manufactured from a relatively hard rubber or other sufficiently durable and wear-resistant material.
- the bottom 52 can include an outer surface 54 that forms the wearing surface of the outsole 50 , and can be contoured to the desired heel and tread pattern.
- the outer surface 54 can be textured to improve the traction and aesthetic appeal of the shoe.
- the upper surface 55 of the outsole may be textured as desired to improve adhesion thereto.
- the outsole 50 can include an outsole recess 56 defined generally from heel to toe of the outsole.
- This recess can be of a first depth 53 in the forefoot and transition to a second depth 57 in the heel.
- the first depth 53 can be such that the midsole 30 nests within the recess 56 to a depth where the medial 33 and lateral 37 forefoot segments, covered with the peripheral allowance 22 , rest flush atop the walls of the recess to provide a clean, finished appearance.
- the second depth 57 in the heel region can be such that the heel cradle at least partially nests within the recess 56 .
- the outsole as shown in FIGS. 1 and 2 can further optionally include toe 51 and heel 59 guards. These guards can be configured to wrap upward and be secured to the toe and heel portions of the upper 20 as desired.
- the toe guard 51 can be configured to abut against the forward portions of the medial 33 and lateral 37 forefoot segments to provide a clean, finished look.
- the heel guard can be configured to abut against the rearward portions of the medial 35 and lateral 39 heel segments.
- the upper 20 is manufactured using generally conventional techniques and apparatus.
- the desired upper material (not shown) is cut to form the upper and its components.
- the multiple upper components, such as the vamp 21 , quarters 23 and backstay 25 are fitted and sewn together.
- An optional liner (not shown) is secured within the upper 20 via adhesives or stitching.
- the midsole 30 described above is manufactured using conventional molding apparatus modified to accommodate the features of the present midsole.
- the allowance 22 of the upper is stitched using a San Crispino stitching method to the segments 33 , 35 , 37 and 39 .
- the lower peripheral allowance 22 is wrapped over the upper surface 72 of the segments, around the edge 74 of the segments, and folded back under against the lower surface 76 of the segment and/or midsole.
- Stitching 70 passes through the lower peripheral allowance, the upper surface, the lower surface and then in reverse direction multiple times to secure the allowance to the respective segment.
- the allowance 22 is stitched to the midsole 30 to further secure the upper and midsole.
- the stitching 70 secures the allowance 22 to the midsole 30 in a 360 degree manner around the entire perimeter of the midsole and/or footwear.
- the outsole 50 is injection molded or pour molded from a hard, durable rubber using conventional molding apparatus. Its construction can be completed before any other components of the footwear are assembled as desired.
- the tread pattern 58 on the lower surface 56 are formed during the molding operation as integral parts of the outsole 50 . With the outsole manufactured, the heel wedge 60 is secured to the outsole 50 . These components may be secured together with cement, adhesive or other attachment means.
- the heel wedge 60 and outsole 50 combination is further cemented to the lower surface of the midsole 30 .
- the flange 64 extends upward from the wedge 60 or outsole 50 , that portion can be cemented to the upper as well.
- the toe and heel guards can further be cemented to the upper as desired as well.
- a footbed 80 can be inserted into the upper to rest in place above the midsole as described above.
- a number of conventional finishing operations may then be performed on the shoe 10 .
- the edges of the heel cradle 60 and the outsole 40 are trimmed and shaped.
- the upper 20 is cleaned, polished and treated as appropriate and necessary.
Abstract
Description
- The present invention relates to footwear and, more particularly, to a footwear construction and method for making the same.
- There is an ongoing effort in the footwear industry to produce footwear that provides flexibility and stability. Such footwear is targeted toward individuals whose lifestyle and/or profession demand high levels of physical activity, for example, traveling on foot for significant distances, or frequently traversing rugged terrain or worksites.
- Conventional footwear constructions, however, provide one of flexibility and stability, but usually not both because the features required for these characteristics typically negate one another. For example, one construction known for its flexibility is a San Crispino construction, which may be incorporated into tactical, military, work or hiking boots. In such a construction, an upper is sewn to a flat, foot shaped insole board. Specifically, a first part of a lower edge of the upper is stitched to a top surface of the insole board. A remaining part of the edge is wrapped over the periphery of the insole-board, and folded back under the board, against the bottom surface of the board. A flat outsole is glued over the bottom surface of the insole board and any part of the upper that is folded against the bottom side of the insole board.
- Although this construction is flexible and aesthetically pleasing, it frequently compromises the stability of the footwear, especially in the heel and ankle region. Moreover, because the insole and outsole are of a substantially uniform thickness from heel to toe of the footwear, there is little or no cushion variation provided for different regions of the foot, which in turn, can compromise the comfort of the shoe.
- Although different constructions exist that provide desired characteristics such as flexibility, there remains an unmet need for a footwear construction that provides the best of both flexibility and stability.
- The aforementioned problems are overcome by the present footwear construction including a midsole that has medial and lateral flanges, and that defines a recess in the heel. An upper can be stitched to the medial and lateral flanges along a lower periphery of the upper.
- In a more specific embodiment, the part of the midsole defining the recess can nest in a heel wedge. An outsole can be secured to the heel wedge generally in the heel region and to the midsole generally in the forefoot region.
- In an even more specific embodiment, medial and lateral flanges can be segmented into separate or non-contiguous heel and forefoot flange segments. The heel wedge can include a concealment flange disposed adjacent the upper in the area between the heel and forefoot flange segments.
- In an even more specific embodiment, a foot bed interfits over the midsole, and nests at least partially within the heel recess. Optionally, the midsole can be constructed from a dual density material, with a softer density material being located in the forefoot region, generally below the ball of a wearer's foot.
- The footwear construction is manufactured by: providing an upper and including a peripheral allowance; joining the peripheral allowance with a midsole including a medial forefoot flange segment and a medial heel flange segment, and a lateral forefoot flange segment and a lateral heel flange segment, the midsole including a heel region and defining a heel recess in the heel region; and joining an outsole with the midsole. Optionally, a heel wedge can be positioned between the midsole and outsole in the heel region. Further optionally, a foot bed can be positioned over the midsole and at least partially in the heel recess.
- The present footwear construction provides an unparalleled combination of flexibility and stability. In the forefoot region, the medial and lateral midsole flanges stitched to the upper makes this region flexible, yet well-supported. In the heel region of the footwear, the midsole heel recess provides extraordinary stability for the ankle and heel of a wearer. Further coupled with an optional heel wedge, the footwear becomes even more stable, but still capable of absorbing heel shock.
- These and other objects, advantages and features of the invention will be more readily understood and appreciated by reference to the detailed description of the invention and the drawings.
-
FIG. 1 is side elevational view of an article of the present footwear construction; -
FIG. 2 is an exploded perspective view of the footwear; -
FIG. 3 is a sectional view of the footwear taken along line 3-3 ofFIG. 1 ; -
FIG. 4 is a sectional view of the footwear taken along line 4-4 ofFIG. 1 ; -
FIG. 5 is a sectional view of the footwear taken along line 5-5 ofFIG. 1 ; and -
FIG. 6 is a bottom perspective view of the footwear showing the upper joined with the midsole. - I. Overview
- A shoe incorporating an embodiment of the footwear construction is shown in
FIG. 1 and generally designated 10. For purposes of the disclosure, the construction is described in connection with a ¾ height tactical boot; however, the construction is well suited for use with any other type of soled footwear. - In general, the
shoe 10 includes an upper 20, amidsole 30 and anoutsole 50. Anoptional heel wedge 60 can be included, but is not required. The midsole, shown better inFIG. 2 , includes amedial flange 32 and alateral flange 36, which optionally can be subdivided into a medialforefoot flange segment 33 and a medialheel flange segment 35, and a lateralforefoot flange segment 37 and a lateralheel flange segment 39, respectively. The midsole can also define aheel recess 34. The upper can include a lowerperipheral allowance 22, which can be secured to at least one of the flange segments noted above. - As used herein, the term “arch region” refers generally to the portion of the shoe corresponding to the arch of the wearer's foot; the term “forefoot region” refers generally to the portion of the shoe forward of the arch region corresponding to the forefoot (e.g., the ball, phalanges, and toes) of a wearer's foot; and the term “heel region” refers generally to that portion of the shoe rearward of the arch region corresponding to the heel of the wearer's foot. The
forefoot region 82,arch region 84 andheel region 86 are generally identified inFIG. 1 , however, it is to be understood that delineation of these regions may vary depending upon the configuration of the footwear. - II. Construction
- The components of the
construction 10 will now be described. To begin, the upper 20 is generally conventional and will not be described in detail. Suffice it to say that the upper 20 includesvamp 21,quarters 23 and backstay 25. With reference toFIG. 2 , the upper 20 includes a lower portion that transitions to anallowance 22, also referred to as a peripheral allowance. Theperipheral allowance 22 is joined with themidsole 30 as described in more detail below. Such joining may be accomplished by stitching, stapling, cementing, riveting, or any other type of fastening. The upper 20 can be manufactured from leather, canvas, nylon, combinations of these materials, or other suitable materials, and can include a liner, waterproof or otherwise, (not shown) or other conventional accessories. - The midsole includes a
medial flange 32 and alateral flange 36. Themedial flange 32 can be segmented into a medialforefoot flange segment 33 and a medialheel flange segment 35. The medialforefoot flange segment 33 and a medialheel flange segment 35 can be non-contiguous with one another or separated from one another by a distance. In the embodiment shown, afirst recess 43 separates the segments. Thelateral flange 36 can be segmented into a lateralforefoot flange segment 37 and a lateralheel flange segment 39. The lateralforefoot flange segment 37 and a lateralheel flange segment 39 can also be non-contiguous with one another or separated from one another by a distance. In the embodiment shown, asecond recess 45 separates these segments. Although not shown, the lateral and medial segments can traverse the heel and/or toe of the footwear and connect with one another as desired. In such an embodiment, thetoe 51 andheel 59 guards can be eliminated and/or shortened. - As shown in
FIG. 2 , themidsole 30 can define aheel recess 34. Thisheel recess 34 can be defined in the heel region of the footwear and extend forward to the arch region, and in some cases, the forefoot region as desired. Theheel recess 34 can be configured to fit at least partially in theheel wedge recess 62, described below, and to receive at least the foot bed, described below. - The
midsole 30 can optionally include aridge 47 on its bottom surface that cooperates with aforward portion 66 of theheel wedge 60 to position themidsole 30 over theoutsole 50 and/orheel wedge 60. - The
midsole 30 can be constructed from one or more materials, each of a different density. For example, theflanges portion 31 of the midsole corresponding to the center of the wearer's foot along the axis of the foot, and/or corresponding to the ball of the wearer's foot, can be constructed from a softer EVA or softer rubber to provide improved flexibility and/or cushion in this area. Optionally, certain components, such as the flanges can be constructed from a completely different material, such as polyurethane, where it is expected that those components will undergo additional structural stresses, for example, where theflanges - The upper 20 can be joined with the
midsole 30. In the embodiment shown, theperipheral allowance 22 can be stitched to thesegments FIGS. 3-5 , the lowerperipheral allowance 22 can be wrapped over theupper surface 72 of the segments, around theedge 74 of the segments, and folded back under against thelower surface 76 of the segment and/or midsole.Stitching 70 can pass through the lower peripheral allowance, the upper surface, the lower surface and then in reverse direction multiple times to secure the allowance to the respective segment. This stitching can remain visible, as shown inFIG. 1 to enhance the aesthetics of the footwear as desired. - In the regions between the segments, for example, in the
recesses FIG. 5 ), theallowance 22 can be stitched directly to themidsole 30, i.e., not the segments, to further secure the upper and midsole. Thestitching 70 in this region can pass through themidsole 30 andallowance 22, and then back through themidsole 30, multiple times to secure the upper to the midsole. Thestitching 70 can then transition to pass through the segments on opposite sides of therecesses arch region 74, thestitching 70 can be concealed as desired, for example by theflange 64, as described below. - The upper 20 and
midsole 30 can be joined with other fastening mechanisms, such as cement, rivets, staples and the like as desired. - An
optional footbed 80 can be inserted in the interior of thefootwear 10 and placed above themidsole 30. Thefootbed 80 can rest at least partially in theheel recess 34 in the heel and/or arch regions as desired. Thefootbed 80 can rest above themidsole 30 in the forefoot region. - The
footwear 10 can include anoptional heel wedge 60. The heel wedge shown inFIGS. 2-5 is a separate component adapted to fit between themidsole 30 and theoutsole 50, generally in at least theheel region 86 of the footwear. However, the heel wedge can also be constructed to be an integral part of the outsole as the application requires. Theheel wedge 60 can be constructed of a cushioning material, such as EVA, to improve cushioning in the heel and/or arch regions of the footwear. Theheel wedge 60 can alternatively be constructed from a denser material, such as polyurethane to add stability to regions of the footwear as desired; As shown, theheel wedge 60 includes a secondary recess, also referred to as aheel wedge recess 62. Thisheel wedge recess 62 can be configured to receive therein themidsole 30 in theheel 76 and/orarch 74 regions. - As shown in
FIGS. 1 and 2 , therecess 62 is configured so that at least a portion of themidsole 30 defining theheel recess 34 fits in therecess 62. Optionally, thesecondary recess 62 can be of a depth such thatmidsole 30 in the heel region nests within therecess 62 so that the medialheel flange segment 35 and lateralheel flange segment 39 protrude over the sides of the recess to provide an aesthetically pleasing and flush contour with the remainder of theheel wedge 60 that is visible. - The
heel wedge 60 can also include at least one upwardly extendingflange 64. Thisflange 64 can extend upward on both the medial and lateral sides of thefootwear 10 as the application requires. As shown inFIG. 2 ,flanges 64 can extend upward between the medialforefoot flange segment 33 and a medialheel flange segment 35, as well as between the lateralforefoot flange segment 37 and a lateralheel flange segment 39. Where these segments form recesses 43, 45 therebetween, theflanges 64 can be disposed within those recesses on opposite sides of the footwear, respectively. Theflanges 64 can also be of a height such that they extend above theflanges footwear 10. Alternatively, theoutsole 50 can include upwardly extending flanges (not shown) that are positioned and operate similarly to theflanges 64 of the heel wedge described above. - Further optionally, the
heel wedge 60 can include an internal shank (not shown) constructed of steel plastic or other material to add the desired structural rigidity to the footwear as desired. Optionally, the shank can be simply secured to the bottom of the heel wedge in thearch region 74 of the shoe. The shank can be secured to other components of the shoe as desired, and may overlap with the other regions, for example, theforefoot 72 region andheel 76 region. - The
outsole 50 is manufactured from a relatively hard rubber or other sufficiently durable and wear-resistant material. The bottom 52 can include anouter surface 54 that forms the wearing surface of theoutsole 50, and can be contoured to the desired heel and tread pattern. Theouter surface 54 can be textured to improve the traction and aesthetic appeal of the shoe. Optionally, theupper surface 55 of the outsole may be textured as desired to improve adhesion thereto. - As shown in
FIGS. 1 and 2 , theoutsole 50 can include anoutsole recess 56 defined generally from heel to toe of the outsole. This recess can be of afirst depth 53 in the forefoot and transition to asecond depth 57 in the heel. Thefirst depth 53 can be such that themidsole 30 nests within therecess 56 to a depth where the medial 33 and lateral 37 forefoot segments, covered with theperipheral allowance 22, rest flush atop the walls of the recess to provide a clean, finished appearance. Thesecond depth 57 in the heel region can be such that the heel cradle at least partially nests within therecess 56. - The outsole as shown in
FIGS. 1 and 2 can further optionally includetoe 51 andheel 59 guards. These guards can be configured to wrap upward and be secured to the toe and heel portions of the upper 20 as desired. In one embodiment, thetoe guard 51 can be configured to abut against the forward portions of the medial 33 and lateral 37 forefoot segments to provide a clean, finished look. Likewise, the heel guard can be configured to abut against the rearward portions of the medial 35 and lateral 39 heel segments. - III. Manufacture and Assembly
- Manufacture of the
footwear 10 will now be described with reference toFIGS. 1-5 . The upper 20 is manufactured using generally conventional techniques and apparatus. The desired upper material (not shown) is cut to form the upper and its components. The multiple upper components, such as thevamp 21,quarters 23 andbackstay 25, are fitted and sewn together. An optional liner (not shown) is secured within the upper 20 via adhesives or stitching. - The
midsole 30 described above is manufactured using conventional molding apparatus modified to accommodate the features of the present midsole. Theallowance 22 of the upper is stitched using a San Crispino stitching method to thesegments FIGS. 3-5 , the lowerperipheral allowance 22 is wrapped over theupper surface 72 of the segments, around theedge 74 of the segments, and folded back under against thelower surface 76 of the segment and/or midsole.Stitching 70 passes through the lower peripheral allowance, the upper surface, the lower surface and then in reverse direction multiple times to secure the allowance to the respective segment. In the regions between the segments, e.g., in therecesses allowance 22 is stitched to themidsole 30 to further secure the upper and midsole. In the optional embodiment shown inFIG. 6 , thestitching 70 secures theallowance 22 to themidsole 30 in a 360 degree manner around the entire perimeter of the midsole and/or footwear. - The
outsole 50 is injection molded or pour molded from a hard, durable rubber using conventional molding apparatus. Its construction can be completed before any other components of the footwear are assembled as desired. The tread pattern 58 on thelower surface 56 are formed during the molding operation as integral parts of theoutsole 50. With the outsole manufactured, theheel wedge 60 is secured to theoutsole 50. These components may be secured together with cement, adhesive or other attachment means. - In another step, the
heel wedge 60 andoutsole 50 combination is further cemented to the lower surface of themidsole 30. Where theflange 64 extends upward from thewedge 60 oroutsole 50, that portion can be cemented to the upper as well. The toe and heel guards can further be cemented to the upper as desired as well. - With the upper 20,
midsole 30,heel wedge 60 andoutsole 50 assembled into thefootwear 10, afootbed 80 can be inserted into the upper to rest in place above the midsole as described above. - A number of conventional finishing operations may then be performed on the
shoe 10. For example, the edges of theheel cradle 60 and the outsole 40 are trimmed and shaped. The upper 20 is cleaned, polished and treated as appropriate and necessary. - The above descriptions are those of the preferred embodiments of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. Any references to claim elements in the singular, for example, using the articles “a,” “an,” “the,” or “said,” is not to be construed as limiting the element to the singular.
Claims (20)
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US11/065,851 US7197840B2 (en) | 2005-02-25 | 2005-02-25 | Footwear and related method of manufacture |
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US11/065,851 US7197840B2 (en) | 2005-02-25 | 2005-02-25 | Footwear and related method of manufacture |
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US20060191163A1 true US20060191163A1 (en) | 2006-08-31 |
US7197840B2 US7197840B2 (en) | 2007-04-03 |
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US11/065,851 Expired - Fee Related US7197840B2 (en) | 2005-02-25 | 2005-02-25 | Footwear and related method of manufacture |
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US10219583B2 (en) * | 2016-10-27 | 2019-03-05 | Red Wing Shoe Company, Inc. | Footwear with ground conforming supportive chassis |
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